US8968909B2 - Fibrous separation membrane for secondary battery and manufacturing method thereof - Google Patents

Fibrous separation membrane for secondary battery and manufacturing method thereof Download PDF

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Publication number
US8968909B2
US8968909B2 US13/160,849 US201113160849A US8968909B2 US 8968909 B2 US8968909 B2 US 8968909B2 US 201113160849 A US201113160849 A US 201113160849A US 8968909 B2 US8968909 B2 US 8968909B2
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heat
resistant resin
polymer layer
low
melting
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Expired - Fee Related, expires
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US20120251853A1 (en
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Sun Ok Kim
Young Seuck Yoo
Jin Wook Na
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Samsung Electro Mechanics Co Ltd
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Samsung Electro Mechanics Co Ltd
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Assigned to SAMSUNG ELECTRO-MECHANICS CO., LTD reassignment SAMSUNG ELECTRO-MECHANICS CO., LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KIM, SUN OK, NA, JIN WOOK, YOO, YOUNG SEUCK
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    • H01M2/162—
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/44—Fibrous material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/02—Details
    • H01M2/1686—
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/411—Organic material
    • H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/411—Organic material
    • H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H01M50/42—Acrylic resins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/411—Organic material
    • H01M50/414—Synthetic resins, e.g. thermoplastics or thermosetting resins
    • H01M50/426—Fluorocarbon polymers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/411—Organic material
    • H01M50/429—Natural polymers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/449—Separators, membranes or diaphragms characterised by the material having a layered structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/409—Separators, membranes or diaphragms characterised by the material
    • H01M50/449—Separators, membranes or diaphragms characterised by the material having a layered structure
    • H01M50/457—Separators, membranes or diaphragms characterised by the material having a layered structure comprising three or more layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/40—Separators; Membranes; Diaphragms; Spacing elements inside cells
    • H01M50/489—Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties
    • H01M50/491—Porosity
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present invention relates to a fibrous separation membrane for secondary batteries, and a method of manufacturing the same.
  • a secondary battery is a battery which can be reused because it can be recharged using external energy and returned to an original state after being discharged.
  • Such a secondary battery is characterized in that it has high power density, it can do high-power discharge, and it is only slightly influenced by temperature.
  • Such a secondary battery includes the four major components of a cathode active material, an anode active material, an electrolyte and a separation membrane.
  • a separation membrane serves to separate a cathode active material and an anode active material, and is used as an ion transfer passage.
  • a separation membrane since a separation membrane serves to provide an ion transfer passage and prevent foreign matter from moving, it must have pores having a size of several micrometers or less.
  • the wet process is a process of forming pores by phase-separating a solution containing a polymer, a solvent and other components and then stretching the phase-separated product
  • the dry process is a process of forming pores by extruding a polymer and then stretching the extruded polymer.
  • the wet process is advantageous in that pores are non-oriented, but is disadvantageous in that manufacturing costs are high.
  • uniaxial stretching must be conducted in the dry process, the dry process is disadvantageous in that pores are oriented, but is advantageous in that manufacturing costs are low.
  • All of the separation membranes formed by the wet process or the dry process are made of polyolefin-based resins.
  • the separation membrane is generally made of two kinds of resins, namely polyethylene and polypropylene.
  • the separation membrane is produced by mixing the two kinds of resins or laminating them.
  • the separation membrane made of polyethylene is advantageous in the shutdown of a secondary battery because of its low melting point, but is problematic in that it is greatly thermally constricted at high temperature because its melting point is low.
  • the separation membrane made of polypropylene is advantageous in thermal constriction, but is disadvantageous in the shutdown of a secondary battery because of its high melting point.
  • the present invention has been devised to solve the above-mentioned problems, and the present invention intends to provide a fibrous separation membrane for secondary batteries, which can satisfy both heat resistance and stability by using a heat-resistant resin together with a low-melting polymer that can conduct a shutdown function.
  • An aspect of the present invention provides a fibrous separation membrane for secondary batteries, including: a polymer layer which partially melts and blocks pores thereof thus cutting off electric current when a temperature of a secondary battery is increased; and heat-resistant resin layers applied on one side of the polymer layer or both sides of the polymer layer.
  • the polymer layer may be formed of a polymer material having a melting point of 100 ⁇ 180° C.
  • the polymer layer may have a thickness of 5 ⁇ 100 ⁇ m and a porosity of 20 ⁇ 90%.
  • each of the heat-resistant resin layers may be formed of any one selected from the group consisting of aromatic polyesters, polyphosphazenes, polyurethane, polyurethane copolymers including polyetherurethane, cellulose acetate, cellulose acetate butylate, cellulose acetate propionate, polyvinylidene fluoride, perfluoropolymers, polyvinylchloride, polyvinylidene chloride, polyethyleneglycol derivatives, polyoxide, polyvinyl acetate, polystyrene, polyacrylonitrile, and polymethacrylate.
  • each of the heat-resistant resin layers may have a thickness of 1 ⁇ 200 ⁇ m.
  • Another aspect of the present invention provides a method of manufacturing a fibrous separation membrane for secondary batteries, including: forming a polymer layer by electrospinning; and electrospinning a heat-resistant resin solution onto both sides of the polymer layer to form ultrafine-fibrous heat-resistant resin layers on one side of the polymer layer or both sides of the polymer layer.
  • the polymer layer may have a thickness of 5 ⁇ 100 ⁇ m and a porosity of 20 ⁇ 90%.
  • each of the heat-resistant resin layers may have a thickness of 1 ⁇ 200 ⁇ m.
  • the method may further include: conducting press lamination after forming the heat-resistant layers on both sides of the polymer layer.
  • FIG. 1 is a sectional view showing a fibrous separation membrane for secondary batteries according to a first embodiment of the present invention
  • FIG. 2 is a schematic view showing an electrospinning apparatus which can be used to manufacture the fibrous separation membrane for secondary batteries according to the present invention
  • FIG. 3 is a flowchart showing a method of manufacturing the fibrous membrane for secondary batteries according to the first embodiment of the present invention.
  • FIG. 4 is a scanning electron microscope (SEM) photograph showing the morphology of the fibrous separation membrane according to the first embodiment of the present invention.
  • FIG. 1 is a sectional view showing a fibrous separation membrane for secondary batteries according to a first embodiment of the present invention.
  • the fibrous separation membrane for secondary batteries includes a low-melting polymer layer 10 , and heat-resistant resin layers 22 and 22 ′ applied on both sides of the low-melting polymer layer 10 .
  • the low-melting polymer layer 10 conducts a shutdown function of cutting off electric current by blocking pores using the molten low-melting polymer occurring when the temperature of a secondary battery excessively becomes high.
  • This low-melting polymer layer 10 is formed of a polyolefin-based resin or a polymer such as polyethylene (PE), polypropylene (PP) or a copolymer thereof.
  • the low-melting polymer layer 10 be formed of a polymer material having a melting point of 100 ⁇ 180° C., preferably 120 ⁇ 150° C.
  • a polyolefin resin or a polymer is used to form the low-melting polymer layer 10 , but the present invention is not limited thereto. All of the polymer materials having a melting point of 100 ⁇ 180° C. can be used.
  • the low-melting polymer layer 10 has a thickness of 5 ⁇ 100 ⁇ m and a pore size of 1 ⁇ 5000 nm. Further, the low-melting polymer layer 10 has a porosity of 20 ⁇ 90%, preferably 40 ⁇ 60%.
  • the heat-resistant resin layers 22 and 22 ′ are applied on both sides of the low-melting polymer layer 10 , function to allow a separation membrane not to be destroyed by melting when the temperature of a secondary battery is continuously increased even after the low-melting layer 10 conducted a shutdown function, and have a melting point of 180° C. or higher.
  • the heat-resistant resin layers 22 and 22 ′ are made of a polymer having a melting point of 180° C. or having no melting point.
  • the polymer having a melting point of 180° C. or having no melting point may include: aromatic polyesters, such as polyamide, polyimide, polyamideimide, poly(meta-phenyleneisophthalamide), ploysulfone, polyether ketone, polyether imide, polyethylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, and the like; polyphosphazenes, such as polytetrafluoroethylene, polydiphenoxyphosphazene, poly ⁇ bis[2-(2- methoxyethoxy)phosphazene] ⁇ , and the like; polyurethane; polyurethane copolymers, such as polyetherurethane, and the like; cellulose acetate; cellulose acetate butylate; cellulose acetate propionate; polyvinylidene fluoride; perflu
  • the polymer having no melting point is referred to as a polymer that burns without melting even at 180° C. or higher.
  • the fibrous separation membrane for secondary batteries is formed by forming the low-melting polymer layer 10 using electrospinning and then forming the heat-resistant resin layers 22 and 22 ′ on both sides of the low-melting polymer layer 10 using electrospinning.
  • ultrafine fiber is formed when high-voltage electrostatic force is applied to a polymer solution or molten polymer having sufficient viscosity.
  • the low-melting polymer layer 10 and the heat-resistant resin layers 22 and 22 ′ may be formed using meltblown spinning or flash spinning in addition to the electrospinning.
  • meltblown spinning or flash spinning ultrafine fiber is formed by high-voltage electric field and air injection.
  • the electrospinning includes the above-mentioned spinning methods.
  • FIG. 2 is a schematic view showing an electrospinning apparatus which can be used to manufacture the fibrous separation membrane for secondary batteries according to the present invention.
  • the electrospinning apparatus includes a first barrel 100 for storing a low-melting polymer solution, a second barrel 110 for storing a heat-resistant resin solution, a proportioning pump 130 for discharging the low-melting polymer solution or heat-resistant resin solution, a high-voltage generator 140 , and a spinning nozzle 150 connected to the high-voltage generator 140 .
  • the low-melting polymer solution or heat-resistant resin solution discharged through the proportioning pump 130 passes through the spinning nozzle 150 electrically charged by the high-voltage generator 140 to be formed into ultrafine fiber, and the ultrafine fiber is collected on a collecting plate 160 grounded in the form of a conveyor moving at a predetermined speed.
  • FIG. 3 is a flowchart showing a method of manufacturing the fibrous membrane for secondary batteries according to the first embodiment.
  • a low-melting polymer solution is put into a first barrel of an electrospinning apparatus, the low-melting polymer solution is discharged using a proportioning pump, and then a spinning nozzle is electrically charged using a high-voltage generator, thus forming a low-melting polymer layer on a collecting plate grounded in the form of a conveyor moving at a predetermined speed (S 100 ).
  • the low-melting polymer layer formed on the collecting plate is a polyolefin-based resin layer having a thickness of 5 ⁇ 100 ⁇ m and a porosity of 20 ⁇ 90%.
  • a heat-resistant resin solution is put into a second barrel of an electrospinning apparatus, the heat-resistant resin solution is discharged using a proportioning pump, and then a spinning nozzle is electrically charged using a high-voltage generator, thus forming heat-resistant resin layers on both sides of the low-melting polymer layer (S 200 ).
  • ultrafine fiber having a size of several nanometers to several thousands of nanometers can be formed. Further, simultaneously with the formation of ultrafine fiber, the ultrafine fiber is fusion-bonded in the form of a three-dimensional network structure, thus forming the ultrafine fiber into a porous ultrafine fiber web.
  • This porous ultrafine fiber web is ultrathin and ultralight, and the ratio of surface area to volume thereof is higher than that of conventional fiber. Further, the porous ultrafine fiber web has high porosity.
  • a solvent is volatilized during an ultrafine fiber forming process, and pores are formed by the gap between ultrafine fibers, so that uniform pores are obtained, and a solvent extracting process or a pore forming process is not required.
  • the heat-resistant resin solution includes a heat-resistant resin having a melting point of 180° C. or higher such that a separation membrane is not destroyed by melting when the temperature of a secondary battery is continuously increased even after the low-melting layer conducted a shutdown function.
  • the porosity and pore size of the ultrafine fiber layer is greatly influenced by the diameter of fiber.
  • the diameter of fiber becomes small, the porosity of the ultrafine fiber layer becomes low, and the pore size thereof becomes small.
  • the specific surface area of fiber increases, so that the electrolyte storage capacity of the ultrafine fiber layer increases, with the result that the possibility of electrolyte leakage becomes low.
  • the heat-resistant resin layer may have a fiber diameter of 1 ⁇ 3000 nm, preferably 1 ⁇ 1000 nm, and more preferably 50 ⁇ 800 nm.
  • the heat-resistant resin layer may have a pore size of 1 ⁇ 5000 nm, preferably to 1 ⁇ 3000 nm, and more preferably 1 ⁇ 1000 nm. In this case, since electrolyte does not leak from the heat-resistant resin layer, the heat-resistant layer can have a high electrolyte storage capacity.
  • the porosity of the heat-resistant resin layer must not be lower than that of the low-melting polymer layer.
  • the low-melting polymer layer, on which the heat-resistant resin layer is applied can maintain high ion conductivity, thus obtaining excellent cycle characteristics at the time of constituting a secondary battery.
  • the porosity of the heat-resistant resin layer be maintained at 30 ⁇ 95%, preferably 40 ⁇ 90%.
  • the thickness of the heat-resistant resin layer is not particularly limited as long as the thermal constriction ratio of the low-melting polymer layer can be maintained at less than 20%, but the minimum thickness thereof is 1 ⁇ m, and the maximum thickness thereof is the thickness of the low-melting polymer layer.
  • the heat-resistant resin layer may have a thickness of 1 ⁇ 20 ⁇ m, and more preferably 1 ⁇ 10 ⁇ m.
  • press lamination is conducted at a predetermined temperature or lower after the heat-resistant resin layer is disposed on the low-melting polymer layer, or is conducted at a predetermined temperature or lower after the separation membrane of the present invention is disposed between a cathode and an anode (S 300 ).
  • the press lamination must be conducted at the temperature at which the physical properties of the low-melting polymer resin are not deteriorated.
  • inorganic additives may be added to a heat-resistant resin.
  • Examples of the inorganic additives which can be used in the present invention may include metal oxides, metal nitrides and metal carbides, such as TiO 2 , BaTiO 3 , Li 2 O, LiF, LiOH, Li 3 N, BaO, Na 2 O, Li 2 CO 3 , CaCO 3 , LiAlO 2 , SiO 2 , Al 2 O 3 , PTFE, and mixtures thereof.
  • the amount of the inorganic additive may be 1 ⁇ 95 wt %, preferably 5 ⁇ 50 wt %, based on a polymer constituting an ultrafine fiber layer.
  • glass containing SiO 2 may be preferably used as the inorganic additive.
  • both heat resistance and stability can be satisfied because a heat-resistant resin is used together with a low-melting polymer that can conduct a shutdown function.
  • a thin separation membrane can be obtained, so that a secondary battery generates high power, thereby improving the performance of a secondary battery.

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US13/160,849 2011-03-28 2011-06-15 Fibrous separation membrane for secondary battery and manufacturing method thereof Expired - Fee Related US8968909B2 (en)

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KR10-2011-0027784 2011-03-28
KR1020110027784A KR20120109258A (ko) 2011-03-28 2011-03-28 이차 전지 섬유상 분리막 및 그 제조 방법
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